Monolithic module structure to build constructions and method for its manufacture

ABSTRACT

A new monolithic module structure for construction and its manufacture method to build monolithic constructions. The monolithic modules can be easily-transported and easily arranged on the conceived site for the construction of the edification. The method comprises the stages of: a) manufacture of the necessary number of harnesses for the fabrication of modules and panels; b) manufacture of modules, where the foundations are fabricated over which the module exterior walls will be manufactured; c) manufacture of panels and flat roofs and of interior panels, if required, simultaneously to the modules; d) integration of interior panels into the modules; e) assembly of the flat roof over the module walls; f) transport and storage of the already assembled module for its commercialization and distribution. The method permits to obtain construction modules at high volumes to be used for diverse constructions.

FIELD OF THE INVENTION

The present invention refers to methods and systems to build constructions, particularly to methods for the manufacture of construction modules that are integrated from a plurality of harnesses, and in conjunction with a flat roof, it is possible to build a great variety of constructions of the monolithic type, the dimensions, capacities and uses of these constructions are allowed to vary implementing in each module a plurality of panels. The field of application of the present invention is in regard to any construction, particularly constructions of prefabricated houses, classrooms and constructions with ample interior spaces, among others.

BACKGROUND OF THE INVENTION

The traditional construction systems have distinguished themselves by creating edifications at the same place were they will reside through the gradual construction of diverse structural elements; however, these types of methodologies consume too much time, labor and their costs are too high. In this sense, the use of constriction processes for edifications using prefabricated elements, such as panels and diverse support structures that are subsequently assembled, represent superior alternatives, since they significantly reduce the existent inconvenients of the traditional construction systems.

Traditionally, the construction systems for buildings of the prefabricated type, have agreed to manufacture modules coated with concrete, which supported on metallic structures or concrete pillars are used to replace the traditional walls built with thin wall and concrete or any other material of this type to cover empty spaces between flanks of the structural elements of the building.

At the moment diverse solutions of construction systems from prefabricated elements and methods to obtain such are known.

Corredera¹ describes a building construction system that combines traditional or non-structural construction with structural construction, whereby concrete is used in both walls and slabs. According to this system, a concrete slab serves as a foundation means and reinforced concrete structural pillars are arranged thereon. On the other hand, cover plates are used to produce the walls, based on a light concrete which is reinforced using electrically welded mesh. In addition, gypsum panels or similar ones are connected to the inner faces of the walls, thus defining the final finish of the interior walls. Furthermore, other panels of expanded gypsum are placed on the interior of the gypsum panels that are connected to the inner faces of the walls in order to provide thermal and acoustic insulation. Finally it is described that the gypsum panels or similar are also provided on the cover plates corresponding to the slabs and in this case, the panels are humidity proof and are used to form the apparent face of the ceilings.

Another system that shows the limitations of the inventions in this field is described by Grace², in which convertible buildings and the methods for their production are divulged. Particularly this system refers to a building construction method that comprises the stages of the construction of a floor, the construction of the walls over the floor and above them the construction of the ceiling, where at least one of the walls contains at least one opening to pass though it. Likewise mechanic and electric internal connections are fixed at least alongside the floor, the walls, the openings and the roof on a predetermined route and are connected to the corresponding external connections. Another step is to cover the mechanic and electric internal connections with detachable adornments that assume the appearance of aesthetic or functional counterparts that are found in non-convertible apartments, in such a way that the mechanical and electrical routes are not perceived, but are always accessible to be transformed without having to demolish the floor, the ceiling or the walls.

However the described systems above do not eliminate the necessity to produce the majority of construction elements, such as walls or structural elements, on the site where the building will reside.

Another alternative to create edifications in less time is represented by the construction systems that create inhabitable modules prefabricated outside the site where buildings will reside, and which will be later transported from the factory to the construction site where they will be mounted and assembled.

In this sense, Olesch³ describes modular transportable edifications created from diverse elements previously constructed within a factory, and which are assembled in the site where the building will reside. The edification is created by the assembly of one factory module that is joined to a reinforced foundations previously placed on the terrain, placing horizontal and vertical segments that are assembled on the module to create habitable spaces attached to the main module. In this case, all the construction elements are made with light material panels (for example wood) and are reinforced with fillings of dense materials to provide them with resistance.

De Quesada⁴ describes multi-floor edifications made by the assembly of diverse modules composed of floor and roof segments connected among each other through a plurality of vertically extended columns that are placed on the corners of the module, in such a way that the columns, as well as the floor and the roof have assembly means which permits to connect them with other modules of similar dimensions. Once the structure of the module has been made, the walls are manufactured placing panels of diverse materials, generally light, that permit to produce the complete module.

Vicino⁵ describes modular monolithic construction structures made from demouldable molds made with rigid external matrices and internal inflatable and collapsible molds, allowing the molding of the module form. The modules are integrated with the application of a gypsum layer covered by a reinforcement steal fiber layer, which is formed over the exterior walls of the internal collapsible mold where the molding segments for doors and windows are temporarily placed. Subsequently, over the settled layers of material the external mold is placed creating a space between this and the layers, the empty space is filled with cementing material that is submitted to a curing and drying process. Over the cured and dried surface obtained, panels of diverse materials (wood, for example) are placed in order to form the walls, which contain a layer of gypsum that permits the joining of the surfaces. Finally the obtained structure, fit with a roof, walls, doors and windows, is joined with a foundations slab previously formed to create the complete module.

Hopkins⁶ describes modular prefabricated structures that can be assembled between each other to create edifications of various floors and stories. The non monolithic modules are designed to vertically align themselves one above the other and are fit with assembly means to generate the building; in addition they are composed of a plurality of panels, which configure the habitable space of the edification's interior. The walls formed by semi-light materials, are assembled over a monolithic concrete slab to create the first edification level over which similar modules are placed later on.

Coday⁷ describes monolithic construction modules prefabricated with concrete composed of a vertical wall, a horizontal roof and a pair of support structures in the way of columns fixed to the roof and localized on the opposite side of the wall. Panels of diverse materials can be placed over the monolithic structure, as well as diverse systems to provide residence services. Such modules can be placed one above the other or else adjacent to each other to create diverse constructions.

The former systems allow the transport and assembly of the module at the edification residence site, with which the inconvenients of the traditional systems and of assembly of prefabricated structural elements are eliminated, despite that such systems have the inconvenient of using light materials for the walls, thus the residences formed by such modules have a reduced stability, are less durable and don't have a convenient structure for environments with extreme ambient temperatures.

It is thus desirable to rely on efficient construction systems that allow the creation of stable and trusted edifications from prefabricated elements such as modules, to build durable, flexible and easily transportable monolithic constructions, which at the same time represent structural and economic advantages.

OBJECTIVES OF THE INVENTION

One of the objectives of the present invention is to provide prefabricated construction modules whose functional and structural resistance characteristics allow the edification of monolithic constructions of long durability that fulfill the quality and security standards established for such constructions.

Another objective of the present invention is to provide easily transportable prefabricated construction modules that can be used as structural elements for the generation of durable monolithic edifications, of great stability and that efficiently insulate the residences from the environment.

Another objective of the present invention is to provide prefabricated construction modules for versatile constructions that may be combined among each other to generate multiple construction types according to the particular construction necessities.

Another objective of the present invention is to provide with a module fabrication method for monolithic constructions, from which modules are obtained whose functional and structural resistance characteristics allow the construction of long durable buildings that fulfill the quality and security standards established for such constructions.

Another objective of the present invention is to provide with a module fabrication method for monolithic constructions that allows the fabrication of such modules at high volumes and competitive costs.

Another objective of the present invention is to provide with a module fabrication method for monolithic constructions whereby the obtained modules can be stored, transported and placed in a fast and easy way at the places originally conceived for each stage.

Even another objective of the present invention is to provide with a module fabrication method for monolithic constructions, so that through the obtained modules it is possible to construct buildings of creative and sustainable solutions for the necessities of an increasing and demanding society like ours.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1. Shows a flow chart where the manufacture units to generate monolithic modules equipped with interior panels are represented.

FIG. 2. Shows a flow chart where the workstations are represented, as well as the stages and sub-stages to generate monolithic modules equipped with interior panels.

FIG. 3. Shows a flow chart where the manufacture units to generate monolithic modules equipped with columns are represented.

FIG. 4. Shows a flow chart where the workstations are represented, as well as the stages and sub-stages to generate monolithic modules equipped with columns.

FIG. 5. Shows the disposition of the diverse elements to generate the foundation slab of the monolithic module.

FIG. 6. Shows the foundation slab of the monolithic module.

FIG. 7. Shows the preparation foundation slab to receive the internal mold to form the walls of the monolithic module.

FIG. 8. Shows the disposition of the internal mold to form the walls of the monolithic module on the foundation slab.

FIG. 9. Shows the disposition of structural harnesses for the walls, as well as molds of windows and door on the internal mold.

FIG. 10. Shows the disposition of the external mold on the ordering shown in FIG. 9 and the provision of cellular concrete for the formation of the walls of the module.

FIG. 11. Shows the sub-module before (a) and later (b) of the joint of the interior panel.

FIG. 12. Shows the disposition of the diverse elements to generate the slab of roof of the monolithic module.

FIG. 13. Shows the monolithic module with interior panel and roof.

FIG. 14. Shows the transport of monolithic modules by means of a vehicle of heavy load.

FIG. 15. Shows the positioning of monolithic modules in the construction site.

FIG. 16. Shows the construction generated after the joint and union of the monolithic modules.

FIG. 17. Shows a frontal view of the location of the structural harness of the lateral wall of module II of the example 1 on the slab foundation and the internal mold for walls.

FIG. 18. Shows an isometric view of the sanitary harness.

FIG. 19. Shows a frontal view of the joint between the structural harness and the electrical harness of the lateral wall of module I of example 1.

FIG. 20. Shows the elements of union and joint of the interior panel to the wall.

FIG. 21. Shows the elements of union and joint of the interior panel to the slab foundation.

FIG. 22. Shows the elements of union and joint of the wall to the roof slab, before (a) and later (b) of the joint.

FIG. 23. Shows an isometric view of sub-module I of example 1.

FIG. 24. Shows an isometric view of sub-module II of example 1.

FIG. 25. Shows a frontal view of the left lateral wall of module II of example 1.

FIG. 26. Shows a frontal view of the facade of the construction generated after the joint of modules I and II of example 1.

FIG. 27. Shows a superior view of the construction generated after the joint of modules I and II of example 1, in the site of residence of the construction.

FIG. 28. Shows an isometric view of the frontal structural harness of module II of example 2.

FIG. 29. Shows an isometric view of the frontal structural harness of module I of example 2.

FIG. 30. Shows an isometric view of the posterior structural harness of module II of example 2.

FIG. 31. Shows a frontal view of the joint between the structural harness and the electrical harness of the lateral wall of module I of example 2.

FIG. 32. Shows a superior view of the structural harness of the roof slab of example 2.

FIG. 33. Shows a superior view of the roof slab of example 2.

FIG. 34. Shows the foundation slab of modules I and II of example 2.

FIG. 35. Shows the structural harness of the foundation slab of modules I and II of example 2.

FIG. 36. Shows an isometric view of the structural beam of the foundation slab of the modules.

FIG. 37. Shows an isometric view of sub-module I (left) and sub-module II (right) of example 2.

FIG. 38. Shows a superior view of the disposition of the stonewares of foundation slabs of modules I and II of example 2 after its union and assembles.

FIG. 39. Shows the elements of union and joint of the wall to the roof slab of the modules of example 2, before (a) and later (b) of the joint.

FIG. 40. Shows a frontal view of the frontal wall of module I of example 2, distinguishing the union between the beam of roof and the column.

FIG. 41. Shows a superior (a) and lateral (b) view of the union elements and joint of the beam of roof to the column.

FIG. 42. Shows a frontal view of the right lateral space of module I of example 2.

FIG. 43. Shows a frontal view of the facade of the construction generated after the joint of modules I and II of example 2.

FIG. 44. Shows a superior view of the interiors of the construction generated after the joint of modules I and II of 2 example as well as the disposition of the furniture.

FIG. 45. Shows a graph of the temperature reached by the exposed surface to fire of walls elaborated with diverse construction materials. It is observed a wall of cellular material (A), expert brick (B), block (C), pumicita brick (D) and hydraulic concrete (E).

FIG. 46. Shows a graph of the temperature reached by the non-exposed surface to fire of walls elaborated with diverse construction materials. It is observed a wall of cellular material (A), expert brick (B), block (C), pumicita brick (D) and hydraulic concrete (E).

FIG. 47. Shows a graph of the values of termal test (BTU in ft² Fh) reached by a wall of cellular material (A), expert brick (B), block (C), pumicita brick (D) and hydraulic concrete (E).

FIG. 48. Shows a superior view of the interiors of a house of 21 m² elaborated from 1 monolithic module of 3×7 mts.

FIG. 49. Shows a superior view of the interiors of a house of 24 m² elaborated from 1 monolithic module of 3×8 mts.

FIG. 50. Shows a superior view of the interiors of a house of 36 m² elaborated from 2 monolithic modules of 3×6 mts.

FIG. 51. Shows a superior view of the interiors of a house of 36 m² elaborated from 2 monolithic modules of 3×4.4 mts and 3×7.7 mts.

FIG. 52. Shows a superior view of the interiors of a house of 39 m² elaborated from 2 monolithic modules of 3×6.7 mts y 3×6.3 mts.

FIG. 53. Shows a superior view of the interiors of a house of 57 m² elaborated from 3 monolithic modules of 3×5.5 (2) and 3×7 mts.

FIG. 54. Shows a superior view of the interiors of a scholar bathrooms of 48 m² elaborated from 2 monolithic modules of 3×8 mts.

FIG. 55. Shows a superior view of the interiors of a scholar dinning room of 96 m² elaborated from 4 monolithic modules of 3×8 mts.

FIG. 56. Shows a superior view of the interiors of a conference room of 48 m² elaborated from 2 monolithic modules of 3×8 mts.

FIG. 57. Shows a superior view of the interiors of a community center of 144 m² elaborated from 6 monolithic modules of 3×8 FIG. 58. Shows a superior view of the interiors of a house of 84 m² elaborated from 4 monolithic modules of 3×8.

DETAILED DESCRIPTION OF THE INVENTION

Contrary to the function of the modules known until today, which is reduced solely to their utilization as false walls, the present invention describes the creation of pre-constructed modules that are used as structural elements in a construction, from which and in all possible combinations with a plurality of interior panels used at convenience for space and functionality, define by themselves monolithic structures of construction, which can be easily transported, easily arranged on the conceived site for the construction of the edification, and that above all result in an option that is economic, fast in its process, and versatile, so as to adapt to the different construction necessities of the communities where it is implemented.

The modules of the present invention provide a thermal and acoustic insulation to the residence, superior to the one obtained by traditional construction systems, at the same time they provide with structural stability and construction durability, which translates into security of the created edifications. To obtain the invention modules light cementing materials that also provide structural stability are used, allowing thus a substantial reduction in the weight of the manufactured modules making their transport and assembly at the construction site an easy task. Moreover, the modules can be manufactured in different sizes and assembled among each other, with which multiple combination options can be created to produce buildings of different applications, for example houses, classrooms, multiple use rooms, dinner rooms, community centers, additional bathroom modules, etc.

The invention modules (FIG. 13) comprise a foundations slab (25) over which the module walls (23) are placed, the walls composing a single space between each other and are integrated into the foundations using union means fitted on the foundations (5). The module is completed assembling a flat roof slab (32) over the walls (23) using assembly means fitted on the walls and the flat roof (FIG. 22). Alternatively the module includes interior panels (21) manufactured with the same material as the walls and which can be placed to delimit specified habitable zones depending on the type of building. This configuration allows a more structural solidity of the edification and a greater versatility since the modules can be combined among each other.

The modules can have openings for their functioning, such as doors (38) and windows (37) that are created while the module walls are being obtained. Likewise, the modules of the invention contain the necessary mechanic, electric, hydraulic and of gas elements allowing the subsequent installation of sanitary furniture and the use of electrical and gas appliances, depending on the designated use for the edification. For example, the modules can only contain sufficient electric and mechanic elements to create habitable spaces that do not require hydraulic or gas installations.

On the other hand, the characteristics of the invention modules allow the creation of habitable comfortable spaces that can be installed even in areas of extreme heat, as they efficiently isolate the residences from the outside temperature; in this case, the residence temperature is always maintained below the outside temperature in situations of high temperatures.

In relation to the finishes of the module, the internal and external walls, as well as the roof, these can be covered with diverse materials used by conventional finishes, for example gypsum, diverse outdoors resistant coverings or paintings depending on the necessities and specifications of the building required. In this case the finishes of the module are carried out according to the described invention method in one of the module manufacturing working stations.

The characteristics of the invention modules allow their transport and assembly at the edification residence site (FIGS. 14 and 15), thus is not necessary to conduct there the interior and exterior finishes since they were conducted before their installation; likewise the placing of doors and windows is not necessary at the edification site, as they are previously placed and adjusted on the module that is going to be installed.

For effects of the invention, the dimensions of the modules can be those that prove to be convenient for the creation of standard habitable spaces required for each edification type and based on the valid construction norms. However, the advisable module dimensions are comprised between 4 to 8 meters in width and between 3 to 4 meters in length. This allows multiple module combinations, for example combinations of 2 to 6 modules of the same dimensions or of different dimensions, with which edifications can be created that have habitable spaces of at least 21 to 150 m² depending on the requirement of the edification.

To transport the invention module in an easy way, the module has simple fastening elements fitted on the foundations and the flat roof that allow to hold it in its place (FIG. 13). The module fastening elements found on the foundations (8) are aligned with fastening elements localized on the flat roof (27), in such a way that fastening means can go across them, for example a band (33) or sling of resistant material, and surrounds the entire module from its inferior part so that their extremes remain arranged on the superior part of the module (FIG. 15). The extremes of the fastening means that have remained on the superior part of the module are fastened to heavy feed mechanisms to be deposited later in load vehicles (FIG. 14) and to be transferred in a safe way to the place of the construction (FIG. 15).

For effects of the invention, the modules can be obtained by the following stages

I. Manufacture of harnesses, II. Manufacture of sub-modules, III. Manufacture of flat roof and interior panels, IV. Integration of the interior panels into the sub-module, V. Assembly of flat roof over the sub-module walls, and VI. Transport and storage of the finished module.

During the harness manufacture stage, the necessary harnesses for the fabrication of sub-modules, interior panels and flat roofs are manufactured; such harnesses are classified according to their use in structural, electrical, hydraulic, sanitary and of gas. Depending on the type of edification required, the use of hydraulic, sanitary and gas harnesses is optional, the size of these is also optional depending on the size of the desired module.

In the sub-module fabrication stage, the foundation over which the exterior module walls (23) will be created is fabricated (FIG. 5). During this stage a monolithic structure is created by the walls composing a single piece between each other and foundation (FIG. 11). The walls are integrated into the foundations using union means previously fitted on the foundations (5).

The foundations are created using a mold adjustable in size (6) where the diverse harnesses (1, 3, 4, 7), depending on the type of edification to be obtained, as well as the union means (5) posterior to the module walls are placed. Over the described arrangement a high resistance cementing material, for example hydraulic cement, is added (FIG. 6) retiring the foundations mold (6) when the cementing material has settled.

Over the foundations obtained (25) an internal mold adjustable in size (11) is placed (FIGS. 8 and 9). The necessary harnesses for the walls (15), as well as the molds for doors (17), windows (16) and wall holes (vanos) are put over this mold, subsequently an external mold adjustable in size (18) is placed over this structure, with which a space between this and the internal mold (11) is formed (FIG. 10). This empty space is then filled with high resistant and light-weight cementing material (19), retiring the internal (11) and external (18) molds when the added cementing material has fully settled.

In relation to the stage of interior panels (21) and flat roof (32) manufacture, this is carried out simultaneously to the sub-module manufacturing stage, creating the flat roof and the interior panels if they are required for the edification. In case of needing the interior panels, these are integrated into the sub-module to delimitate the habitable spaces of the edification (FIG. 21). The interior panels (21) are obtained in a similar way as the module exterior walls (23), using exclusively a mold adjusted to the appropriate dimensions to generate an empty space that is subsequently filled with cementing material.

With respect to the flat roof (12), this is obtained using a mold adjustable in size (26) where the diverse harnesses (29, 30), depending on the type of edification to be obtained, as well as the union means posterior (FIG. 22) to the module walls are placed. As well as for the foundations (25), a high resistance cementing material is added over the mold (28), obtaining thus a flat roof slab when the cementing material has settled.

Subsequently the flat roof (32) is assembled over the sub-modules walls (23) using union means localized on the walls and on the flat roof (FIG. 22), with which the monolithic module is created (FIG. 13). The module is submitted to conventional internal and external wall finishing processes, waterproofing of walls and roof, placement of doors, windows, and the required electric, hydraulic or gas appliances.

When the invention module is finished, it is stored and transported (FIG. 14) to the site where it is going to be placed. At the site minimal terrain leveling and delimitation tasks are carried out where the module or modules required for the desired edification and in accordance with the architectonic project are going to be placed (FIG. 15).

In one of the embodiments of the invention, the modules contain reinforcement columns (61) that are localized at the extremes of the site where one module is joined to the other (FIG. 37). The columns (61) are preferentially added to the invention modules when these are used to create buildings with ample habitable spaces that don't necessarily have interior panels to delimit the habitation zones, for example when using several 3×8 m sized modules that are assembled among each other to create classrooms or community centers. In this case, the flat roof slab (32) of this module type has an integrated beam (66) localized in the area where one module is going to be joined to the other (FIG. 42), in such a way that it functions as a structural reinforcement of the monolithic flat roof slab (32) that will be then placed over the module walls (23). For these types of assemblies, the existence of flat roof beams (66), as well as reinforcement module columns (61), allow the creation of a monolithic structure of high resistance and durability.

To create modules that have columns and beams on the flat roof, the next manufacturing method is followed.

I. Manufacture of harnesses, II. Manufacture of sub-modules, III. Manufacture of flat roof and columns, IV. Integration of the columns into the sub-module, V. Assembly of flat roof over the walls and columns of the sub-module, and VI. Transport and storage of the finished module.

The stages I and II of this method are carried out in the same way as the general method described beforehand.

With respect to the stage of flat roof (32) and column (61) manufacture, this is carried out simultaneously to the sub-module manufacturing stage (II). The columns (61) are obtained form internal and external molds of specified dimensions; over the internal mold (11) a structural column harness fitted with union means to the walls and the foundations is placed (FIGS. 33 and 39), next the external column mold is placed over and an empty space is formed that is subsequently filled with high resistance cementing material, for example hydraulic concrete. When the cementing material has settled, the internal and external molds are retired, obtaining thus a column (61).

The flat roof (32) is obtained using a mold adjustable in size (26) where the diverse harnesses (29, 30), depending on the type of edification to be obtained, as well as the union means posterior (FIG. 39) to the module walls are placed. During the fabrication of the flat roof slab (32) a beam (66) is placed to reinforce the integrity of the flat roof slab (32), the beam (66) is going to interact directly with the columns (61) for the final assembly of the module (FIG. 33). Over the flat roof mold the high resistance cementing material is added (28) obtaining a flat roof slab when the cementing material has settled.

Subsequently the columns (61) are placed over the foundations (25) resting on the walls (23). The column-foundations-walls union is carried out by the elements of union contained in these elements (FIG. 41). When the columns (61) are installed, the flat roof (32) is assembled over the sub-modules walls (23) using union means localized on the walls and on the flat roof (FIG. 39), with which the monolithic module is produced. Finally the module is submitted to diverse conventional internal and external wall finishing processes, waterproofing of walls and roof, placement of doors, windows, and the required electric, hydraulic or gas appliances. The finished module or modules are stored and transported then (FIG. 14) to the site where they are going to be placed. At the site minimal terrain leveling and delimitation tasks are previously carried out and in accordance with the corresponding architectonic project.

In any of the methods described to obtain the invention modules, the union of each of the module elements is carried out using union means localized in such elements, if possible the union is made by welding since such union means are preferably steal plates build onto specific sites of the structural harnesses that are part of elements of the module. This allows the creation of monolithic solid structures which will translate into the creation of structurally resistant and durable buildings.

In relation to the union of several modules to create the edification, this is carried out using union and metallic fastening modes that permit to join the module (FIG. 38) by retouching the space that may exist between each other with cementing material, on the interior as well as on the exterior of the edification. Likewise the part of the module which is coupled with other modules has union means that allow the joining to other module by welding.

The invention method is basically carried out using a plurality of working stations that interact between each other to separately generate the diverse elements that constitute the invention module, such elements are obtained simultaneously and in series consequently allowing an increment in the production of modules of interest. As it can be appreciated in FIGS. 1 to 4, diverse manufacturing units constituted at the same time in working stations are distinguished in compliance with the elements that are produced in them.

-   -   The harness manufacturing unit (FIGS. 1 and 3) is dedicated to         the production of the required harnesses for the creation of         modules,     -   The panel manufacturing unit (FIGS. 1 and 3) is dedicated to the         fabrication of interior panels, flat roofs, and columns, and is         constituted by stations of: production of flat roofs (station         F), production of interior panels (station G), curing of flat         roof and interior panels (station H) and transportation of flat         roof and interior panels (station I) (see FIG. 2). In one of the         embodiments of the invention the panel manufacturing unit is         constituted by the stations of flat roof and columns production         (station F and G), curing of the flat roof and columns         (station H) and transportation of roof top and columns         (station I) (see FIG. 4),     -   The module manufacturing unit (FIGS. 1 and 3) is dedicated to         the fabrication of invention modules constituted by the stations         of: internal mold preparation (station A), production of         foundations (station B), production of sub-module (station D),         and assembly and finishing of the module (station E) (see FIGS.         2 and 4),     -   The manufacturing unit for the fabrication of cementing material         or concrete factory (FIGS. 1 and 3) is dedicated to the         obtaining of cementing materials that will be used for the         fabrication of modules, this unit provides concrete of high         resistance, for example hydraulic concrete, in the stations of:         production of foundations (station B) and flat roofs (station F)         (FIG. 2), while in one of the embodiments of the invention it         provides the same type of concrete to production stations of         flat roofs and columns (station F) (FIG. 4), and provides         concrete of high resistance and low density to production         stations of sub-modules (station C) and production of interior         panels (station G) (FIGS. 2 and 4), and     -   The storage unit dedicated to the storage of concluded modules         (FIGS. 1 and 3). From this zone, the modules are packed and         prepared for their transport by heavy load vehicles, for example         load vehicles equipped with platforms, to the construction         residence area.

Within the invention module, diverse elements that constitute the monolithic module can be distinguished. The module will be subsequently installed at the construction site combining or not other modules of similar dimensions and characteristics to create the desired edification. As FIG. 13 shows, the monolithic module includes the foundations (25), walls composing a single piece (23), openings for doors (24) and windows (22), flat roof (32), and fastening elements which allow the transport to the edification residence site (8, 27). Likewise the module can contain any of the dimensions and interior distributions that result convenient (see FIGS. 27, 44 and 48 to 58) to facilitate its combination and for the creation of edifications with the required habitable spaces, in accordance with the architectonic project of interests.

In other of the invention embodiments, the obtainment of modules to build monolithic constructions corisists of the following stages:

I. Manufacture of Harnesses.

In this stage the different types of harnesses are manufactured, preferably in a harness manufacturing unit (see FIGS. 1 and 2), which are integrated to each one of the parts that form the module obtained in accordance with the present invention, so to say, in this stage harnesses for the Flat roof, Interior Panel, Laying of Foundations and Exterior Walls are manufactured, in particular as it is detailed here:

Flat Roof.

The manufacture of 4 harnesses is contemplated, a structural mesh harness, an electrical harness, a structural armor harness and a union plates harness.

The structural mesh harness for the flat roof is manufactured by the following steps:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out, -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the harness specifications; -   3. The fastening of reinforcement rods is conducted, -   4. The structural harness identified at the electrical harness     assembly station is installed (which has been already     prefabricated). In this station the electrical harness (FIG. 19) is     integrated into the structural mesh; -   5. Already wired flexible poliducts are connected to electrical     boxes and plastic ties are placed on the tips of the cables; -   6. The sealing of electrical boxes, the identification and     verification of the quality of the complete harness is carried out;     and -   7. The integrated harness is transported to the harness warehouse.

The electrical harness for the flat roof (FIG. 19) is manufactured by the following steps:

-   1. The assembly of electrical boxes is conducted, which consists in     the perforation of the boxes and the fastening of the fixation rods,     which have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the cutting of the poliduct is     carried out according to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct wiring is carried out according to the given     specifications, and -   5. The electrical harness is inspected and it is transported to Step     4 of the structural mesh harness for the flat roof.

The structural armor harness for the flat roof is manufactured by the following steps:

-   1. Using a universal cutting machine, the necessary rods and     wire-rods are cut to the specified dimensions, -   2. The fastening of the armor is made using annealed wire, and -   3. The armors are inspected and they are transported to the harness     warehouse.

The union plates harness for the flat roof (FIG. 22) is manufactured by the following steps:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

Interior Panel.

For the Interior Panel, a structural mesh harness, an electrical harness and a union plates harness will be manufactured.

The structural mesh harness for the interior panel is manufactured by the following steps:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the mesh is carried out. -   2. The mesh is placed in a workstation to carry out the cutting of     leftovers and overlaps in agreement with the specifications of the     module, -   3. The fastening of the reinforcement rods is carried out, -   4. The structural harness identified at the electrical harness     assembly station is installed (which has been already     prefabricated). In this station the electrical harness is integrated     into the structural mesh, -   5. Already wired flexible poliducts are connected to electrical     boxes and plastic ties are placed on the tips of the cables; -   6. The sealing of electrical boxes, the identification and     verification of the quality of the complete harness is carried out,     and -   7. The integrated harness is transported to the harness warehouse.

The electrical harness for the interior panel is manufactured by the following steps:

-   1. The assembly of electrical boxes is carried out and consists in     the perforation of the boxes and the fastening of the fixation rods,     which have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the cutting of the poliduct is     carried out to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct is wired according to the given specifications, and -   5. The electrical harness is transported to Step 4 of the structural     mesh harness for the interior panel.

The union plates harness for the interior panel is manufactured by the following steps:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

Foundations

For the foundations 7 different types of harnesses are manufactured, a structural mesh harness, a structural superior mesh harness, an electrical harness, a structural beam harness, a sanitary harness, a union plates harness and a hydraulic harness.

The structural inferior mesh harness (FIG. 35) for the foundations is obtained as follows:

-   1. Using a machine for the fabrication of meshes and wire-rod as raw     material, the electro welding of the mesh is carried out. -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the specifications of the module; -   3. The structural mesh is brought to the next station were the     bending of the corners and the hoisting of the channel steps is     carried out; -   4. The structural inferior mesh harness is inspected and it is     transported to the harness warehouse.

The structural superior mesh harness (FIG. 35) for the foundations is obtained by the following steps:

-   1. Using a machine for the fabrication of meshes and wire-rod as raw     material, the electro-welding of the structural mesh is carried out. -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the specifications of the module, -   3. The structural harness identified at the electrical harness     assembly station is installed (which has been already     prefabricated). In this station the electrical harness is integrated     into the structural superior mesh and the verification of the     quality of the complete harness is carried out, and -   4. The structural superior mesh harness with the integrated     electrical harness is inspected and it is transported to the harness     warehouse.

The electrical harness for the foundations is obtained as follows:

-   1. The assembly of electrical boxes is carried out, which consists     in the perforation of the boxes and the fastening of the fixation     rods, these have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the poliduct cutting is     carried out to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct wiring is carried out in accordance with the given     specified dimensions. -   5. The electrical harness is inspected and it is transported to Step     3 of the structural superior mesh harness of the foundations.

The structural beam harness (FIG. 36) for foundations is obtained by the following steps:

-   1. The cutting of the rod and wire-rod is carried out using a     universal cutting machine and according to the given specifications, -   2. The rod and wire-rod are bent using a universal bending machine, -   3. Finally the bent rods are tied with wire-rod stirrups and     annealed wire to form the beams, and -   4. The beams are inspected and they are transported to the harness     warehouse.

The sanitary harness (FIG. 18) for the foundations is obtained as follows:

-   1. Using a universal cutting machine, the cutting of the PVC pipe is     carried out according to the specified dimensions, -   2. The PVC pipe is adhered in accordance with the given     specifications, -   3. The sanitary harness is inspected and it is transported to the     harness warehouse.

The union plates harness (FIG. 21) for the foundations is obtained by the following steps:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The union plates harness is inspected and it is sent to the     harness warehouse.

The hydraulic harness for foundations is obtained as follows:

-   1. Using a pipe cutting machine, the cutting of the pipe is carried     out according to the specified dimensions, -   2. The joining of the pipe is carried out, which can be done through     welding, thermofusion, or other method depending on the material of     the pipe. -   3. A hermetic test is carried out in accordance with what has been     specified, the hydraulic harness is inspected and it is transported     to the harness warehouse.

Exterior Walls

For the exterior walls, as for the foundations, seven different types of harnesses are manufactured, a structural mesh harness, an electrical harness, a sanitary harness, a hydraulic harness, a gas harness, a union plates harness and a door harness.

The structural mesh harness for the exterior walls (FIG. 17 y 19) is obtained as follows:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out. -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the specifications of the module; -   3. The fastening of the reinforcement rods is carried out on doors,     windows, unloading holes, wall holes, electrical boxes, and the     fastening of enclosure stiffening brackets at corners is carried     out, -   4. The structural harness identified at the electrical harness     assembly station is installed (which has been already     prefabricated). In this station the electrical harness is integrated     into the structural mesh and the quality of the complete harness is     verified, and -   5. The structural mesh harness with the integrated electrical     harness is transported to the harness warehouse.

The electrical harness for the exterior walls (FIG. 19) is obtained by the following steps:

-   1. The assembly of electrical boxes is conducted, which consists in     the perforation of the boxes and the fastening of the fixation rods,     which have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the cutting of the poliduct is     carried out to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct wiring is carried out according to the given     specifications, and -   5. The electrical harness is inspected and it is transported to Step     4 of the structural mesh harness of the exterior walls.

The sanitary harness for the exterior walls is obtained as follows:

-   1. Using a universal cutting machine, the cutting of the PVC pipe is     carried out according to the specified dimensions, -   2. The PVC pipe is adhered in accordance with the given     specifications, and -   3. The sanitary harness is inspected and it is transported to the     harness warehouse.

The hydraulic harness is manufactured as follows:

-   1. Using a pipe cutting machine, the cutting of the pipe is carried     out according to the specified dimensions. -   2. The joining of the pipe is carried out according to the given     specifications, with thermofusion, welding or other method adequate     to the material of the pipe used, and -   3. A hermetic test is carried out in accordance with what has been     specified, the harness is inspected and it is transported to the     harness warehouse.

The gas harness of the exterior walls is obtained as follows:

-   1. Using a universal cutting machine, the cutting of the pipe is     carried out according to the specified dimensions, -   2. The joining of the pipeline is carried out through welding or nut     threading, in compliance with the specifications given according to     the type of pipe material used, and -   3. A hermetic test is carried out in accordance with what has been     specified, the harness is inspected and it is transported to the     harness warehouse.

The union plates harness for the exterior walls (FIG. 22) is as follows:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

The door harness (FIG. 9) is manufactured by the following steps:

-   1. Using a universal cutting machine the metallic profile is cut     according to the specified dimensions, -   2. The manufacture of anchors is performed, which consist on the     cutting of corrugated rod and the bending of it, -   3. The rod for inferior reinforcement is cut using a universal     cutting machine, -   4. The doorframes are manufactured according to the following     operations:     -   i. to weld anchors in profile sections of the door,     -   ii. to weld profile sections to form the doorframe,     -   iii. to weld reinforcement rods on the inferior part,     -   iv. to polish welded frame, and     -   v. to seal frame unions; and -   5. The harness is inspected and it is send to the harness warehouse.

II. Manufacture of Modules.

The process of module manufacture consist of 5 working stations, called A, B, C, D and E, where specific operations are carried out; identified as sub-stages of the manufacture method being as follows (see FIGS. 1 and 2):

Station A.

-   Sub-stage 1. In Station A of the process, a mold of the interior     wall is submitted to a cleaning process, basic maintenance and     application of demoulding oil on the surfaces that have contact with     the concrete, and -   Sub-stage 2. The structural harness of mesh, steal, electrical,     sanitary, (FIG. 18) hydraulic and of gas are assembled over the mold     of the interior wall. In addition, the molds of windows, wall holes     (vanos), doorframes and union plates to the interior panel (FIG. 20)     and flat roof (FIG. 21) are placed over the mold of the interior     wall. All this process is conducted according to the given     specifications.

Station B.

-   Sub-stage 3. The platform and foundations mold are submitted to a     cleaning process, basic maintenance and application of demoulding     oil on the surfaces that have contact with the concrete, and -   Sub-stage 4. A foundations mold is placed over the platform. This     metallic mold is formed by various sections depending on the size of     the foundations to be manufactured and in accordance with the given     specifications. -   Sub-stage 5. The beams of steal rod, which have been prefabricated     in the harness unit, are assembled over the metallic mold. Next, the     structural steal mesh harness, which has also been prefabricated in     the harness unit, is assembled. This structural harness has the     corresponding electrical harness integrated. Subsequently the     hydraulic and sanitary harnesses (FIG. 18) are integrated into the     structural harness. Finally the plates and rods of union are     installed into the walls. These operations are conducted according     to the manufacture drawings. -   Sub-stage 6. In the concrete factory, the normal concrete is     prepared, preferentially the hydraulic concrete according to the     NMX-C155 norm and to the required design characteristics, which is     perfectly compatible with the cellular concrete. The concrete is     distributed in a hopper to the station in order to perform the     adding of the concrete over the foundations mold, -   Sub-stage 7. Once the adding has been completed (FIG. 6), the     vibration of the mixture is carried out to ensure the proper     consistency and distribution of the concrete. Subsequently a finish     and a superficial polish is given in accordance with the given     specifications, and -   Sub-stage 8. Once a finish has been given to the foundations, the     preliminary vapor curing is carried out under temperature, humidity     and time specifications to ensure the adequate setting of the     concrete.

Station C.

-   Sub-stage 9. At the end of the curing process, the platform is moved     to Station C, -   Sub-stage 10. The foundations is demoulded and the mold is returned     to Station B, -   Sub-stage 11. The interior wall mold (coming from Station A) is     placed over the foundations. This mold is metallic and it is     fabricated in one piece. Previously in Station A, the required     harnesses have been assembled over the interior wall mold. In     addition, the molds of windows, wall holes (vanos), doorframes and     the union plates have been placed over the interior wall mold (FIG.     20), -   Sub-stage 12. The exterior wall mold is submitted to a cleaning     process, basic maintenance and application of demoulding oil on the     surfaces that have contact with the concrete, -   Sub-stage 13. The molding of the walls is completed using an     exterior wall mold that is closed over the interior wall mold (FIG.     10). This exterior wall mold is metallic and it is fabricated in two     pieces that are simultaneously slid with such a precision that     allows the hermetic closing of the mold walls. The dimensions of the     walls go in accordance with the given specifications, -   Sub-stage 14. In the concrete factory the cellular concrete is     prepared and it is distributed in a hopper to the station in order     to perform the adding of the concrete over the walls mold, -   Sub-stage 15. When the adding has been completed, the surface is     leveled to ensure the specified slope for the walls, -   Sub-stage 16. The preliminary curing of the walls is carried out,     staying there until the concrete has settled sufficiently. -   Sub-stage 17. After the concrete has settled for a determined time,     the demoulding of the interior wall is carried out and the mold is     returned to Station A. -   Sub-stage 18. The exterior wall mold is opened and it stays in     Station C waiting for the next molding and adding of walls cycle.

Station D.

-   Sub-stage 19. The platform is moved to Station D, -   Sub-stage 20. Once the walls have been demoulded, the final vapor     curing of the module is carried out under temperature, humidity and     time specifications.

Station E.

-   Sub-stage 21. The platform is moved to Station E. -   Sub-stage 22. Once the foundations-walls combination has its nominal     resistance, the process of module integration is carried out,     starting with the preparation of the surface and the assembly of the     interior panel. The interior panel-walls union is carried out     through a welding process of the union plates preciously placed on     the foundations as on the exterior walls and the interior panel     (FIGS. 20 and 21), -   Sub-stage 23. Next, the surface preparation and the assembly of the     flat roof is carried out. The flat roof-walls union is carried out     through a welding process of union plates previously placed on the     walls as on the flat roof (FIG. 22), -   Sub-stage 24. The last phase of the module integration process is     carried out, which consists on the retouching, detailing and sealing     of the already integrated panel, -   Sub-stage 25. Once the module integration process has been carried     out, the platform is moved to the exterior of the factory, -   Sub-stage 26. The module over the platform is dried out at ambient     temperature for a determined time, -   Sub-stage 27. The module is removed from the platform and it is     transported to the module warehouse using a portico-type crane, -   Sub-stage 28. The platform is returned to Station B to start the     cycle again.

III. Manufacture of Flat Roofs and Panels.

Simultaneous to the fabrication of modules, the panel manufacture unit produces the interior panel and the flat roof for the integration of the module. The panel manufacture unit consists of the three workstations, identified as F, G and H, where specific operations are carried out, at the panel manufacture unit, identified as sub-stages of the manufacturing method, being defined as the interrelation of such stages as it is detailed as follows (see FIG. 1):

Station F.

-   Sub-stage 29. The platform and the flat roof mold are submitted to a     process of basic maintenance and application of demoulding oil on     the surfaces that have contact with the concrete, -   Sub-stage 30. The flat roof mold is placed over the platform. This     metallic mold is formed by various sections depending on the size of     the flat roof to be manufactured and in accordance with the given     specifications, -   Sub-stage 31. The polystyrene ‘bovedilla’ is placed over the     platform of the mold. The reinforcement armor and the structural     steal mesh harness, which has been prefabricated in the harness     unit, are placed over the ‘bovedilla’. This structural harness has     the corresponding electrical harness integrated. Finally, the union     plates are installed into the walls (FIG. 22), -   Sub-stage 32. At the concrete factory, the normal concrete is     prepared, which is distributed in a hopper to the station in order     to perform the adding of the concrete over the flat roof mold, -   Sub-stage 33. Once the adding has been completed, the vibration of     the mixture is carried out to ensure the proper consistency and     distribution of the concrete. Subsequently a finish is given, which     includes the configuration of the flat roof fence in accordance with     the given specifications, -   Sub-stage 34. Once the finish has been given to the flat roof, the     preliminary vapor curing is carried out under temperature, humidity     and time specifications to ensure the adequate setting for the flat     roof.

Station G.

-   Sub-stage 35. At the end of the curing process, the platform is     moved to Station G, -   Sub-stage 36. After the setting of the concrete, the flat roof is     demoulded and the mold is returned to Station F, -   Sub-stage 37. The platform and the interior panel mold are submitted     to a cleaning process, basic maintenance and application of     demoulding oil on the surfaces that have contact with the concrete, -   Sub-stage 38. The interior panel mold is placed over the platform.     This metallic mold is formed by various sections depending on the     size of the interior panel to be manufactured and in accordance with     the given specifications, -   Sub-stage 39. The structural steal mesh harness that has been     prefabricated in the harness unit is assembled. This structural     harness has the corresponding electrical harness integrated.     Finally, the union plates are installed on the exterior walls, -   Sub-stage 40. At the concrete factory, the cellular concrete is     prepared, which is distributed in a hopper to the station in order     to perform the adding of the concrete over the interior panel mold, -   Sub-stage 41. Once the adding has been completed the surface is     leveled and a superficial finish is given in accordance with the     specifications, -   Sub-stage 42. Once the finish to the interior panel has been given,     the preliminary vapor curing is carried out under temperature,     humidity and time specifications to ensure the correct setting of     the concrete, -   Sub-stage 43. After the setting of the concrete, the demoulding of     the interior panel is carried out. The mold stays in Station G     waiting for the next molding and adding of the interior panel cycle.

Station H.

-   -   Sub-stage 44. The platform is moved to Station H,

-   Sub-stage 45. At Station H, the final vapor curing is carried out to     the flat roof as well as to the interior panel under temperature,     humidity and time specifications.     IV. Integration of the Interior Panels into the Module.

This stage of the manufacture method consists of two sub-stages, carried out in a working station identified as I, which in detail are explained as follows (see FIG. 1):

Station I.

-   Sub-stage 46. The platform is moved to Station I, -   Sub-stage 47. Using a crane system, the interior panel is     transported to Station E, where the module is assembled.

V. Assembly of the Flat Roof Over the Module Walls.

This stage also identified as the final stage or operational conclusion of the module manufacture method to build monolithic constructions, is carried out as the following sub-stage (see FIGS. 1 and 2):

-   Sub-stage 48. Using a crane system, the flat roof is transported to     Station E where it is assembled over the module walls. Once the     module has been integrated, it is retouched and detailed.

VI. Transport and Storage of the Already Assembled Module for its Commercialization and Distribution (see FIGS. 1 and 2).

-   Sub-stage 49. Once the flat roof and the interior panel have been     integrated into the module, the platform is moved to the exterior of     the factory, -   Sub-stage 50. The platform is returned to Station F to reinitiate     the panel manufacture process.

In other of the invention embodiments, the obtainment of modules equipped with columns and flat roof beams to build monolithic constructions, consists of the following stages:

I. Manufacture of Harnesses.

In this stage the different types of harnesses are manufactured, preferably in a harness manufacturing unit (see FIGS. 3 and 4), which are integrated to each one of the parts that create the module obtained in accordance with the present invention, so to say, in this stage harnesses for the flat roof, foundations, walls and columns are manufactured, in particular as it is detailed here:

Flat Roof (FIGS. 32 and 33).

The manufacture of five harnesses is contemplated, a structural inferior mesh harness, a structural superior mesh harness, an electrical harness, a structural armor harness and a union plates harness.

The structural inferior mesh harness for the flat roof (FIG. 32) is manufactured by the following steps:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out, -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the module-specifications; -   3. The structural mesh is brought to the next station were the     bending of the corners and channel hoisting steps are carried out; -   4. The structural inferior mesh harness is inspected and it is     transported to the harness warehouse.

The structural mesh harness for the flat roof (FIG. 32) is manufactured by the following steps:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out, -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the module specifications; -   3. The fastening of reinforcement rods is conducted, -   4. The structural harness identified at the electrical harness     assembly station is installed; the harness has already been     prefabricated. In this station the electrical harness is integrated     into the structural superior mesh; -   5. Already wired flexible poliducts are connected to electrical     boxes and plastic ties are placed on the tips of the cables; -   6. The sealing of electrical boxes, the identification and     verification of the quality of the complete harness is carried out;     and -   7. The integrated structural superior mesh harness is transported to     the harness warehouse.

The electrical harness for the flat roof is manufactured by the following steps:

-   1. The assembly of electrical boxes is carried out, which consists     in the perforation of the boxes and the fastening of the fixation     rods, these have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the poliduct cutting is     carried out to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct wiring is carried out in accordance with the given     specified dimensions, and -   5. The electrical harness is inspected and it is transported to Step     4 of the structural superior mesh harness for the flat roof.

The structural armor harness for the flat roof is manufactured by the following steps:

-   1. Using a universal cutting machine, the necessary rods and     wire-rods are cut to the specified dimensions, -   2. The fastening of the armor is made using annealed wire, and -   3. The armors are inspected and they are transported to the harness     warehouse.

The union plates harness for the flat roof (FIG. 39), is manufactured by the following steps:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

Foundations (FIGS. 34 and 35.

For the foundations five different types of harnesses are manufactured, a structural inferior mesh harness, a structural superior mesh harness, an electrical harness, a structural beam harness and a union plates harness.

The structural inferior mesh harness for the foundations is obtained as follows:

-   1. Using a machine for the fabrication of meshes and wire-rod as raw     material, the electro welding of the mesh is carried out. -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the specifications of the module; -   3. The structural mesh is brought to the next station were the     bending of the corners and the channel hoisting steps are carried     out; -   4. The structural inferior mesh harness is inspected and it is     transported to the harness warehouse.

The structural superior mesh harness for the foundations is obtained by the following stages:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out, -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the module specifications; -   3. The structural harness identified at the electrical harness     assembly station is installed; the harness has already been     prefabricated. In this station the electrical harness is integrated     into the structural superior mesh and the verification of the     quality of the complete harness is carried out, and -   4. The integrated structural superior mesh harness is transported to     the harness warehouse.

The electrical harness for the foundations is obtained as follows:

-   1. The assembly of electrical boxes is carried out, which consists     in the perforation of the boxes and the fastening of the fixation     rods, these have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the poliduct cutting is     carried out to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct wiring is carried out in accordance with the given     specified dimensions, and -   5. The electrical harness is inspected and it is transported to Step     3 of the structural superior mesh harness of the foundations.

The structural beam harness for foundations is obtained by the following steps:

-   1. The cutting of the rod and wire-rod is carried out using a     universal cutting machine and according to the given specifications, -   2. The rod and wire-rod are bent using a universal bending machine, -   3. Finally the bent rods are tied with wire-rod stirrups and     annealed wire to form the beams, and -   4. The beams are inspected and they are transported to the harness     warehouse.

The union plates harness for the foundations, is manufactured by the following steps:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

Exterior Walls (FIG. 28 to 31).

For the exterior walls three different types of harnesses are manufactured, a structural mesh harness, an electrical harness, and a union plates harness.

The structural mesh harness for the exterior walls is obtained as follows:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out. -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the specifications of the module; -   3. The fastening of the reinforcement rods is carried out on doors,     windows, unloading holes, wall holes (vanos), electrical boxes, and     the fastening of enclosure stiffening brackets at corners is carried     out, -   4. The structural harness identified at the electrical harness     assembly station is installed; the harness has already been     prefabricated. In this station the electrical harness is integrated     into the structural mesh and the quality of the complete harness is     verified, and -   5. The structural mesh harness with the integrated electrical     harness is transported to the harness warehouse.

The electrical harness for exterior walls is obtained by the following stages:

-   1. The assembly of electrical boxes is carried out, which consists     in the perforation of the boxes and the fastening of the fixation     rods, these have been previously cut to the specified dimension, -   2. Using a universal cutting machine, the poliduct cutting is     carried out to the specified dimensions, -   3. Using a cable cutting machine, the cutting of the cable of     varying calibers and colors is carried out according to the     specified dimensions, -   4. The poliduct wiring is carried out in accordance with the given     specified dimensions, and -   5. The electrical harness is inspected and it is transported to Step     4 of the structural mesh harness of the exterior walls.

The union plates harness for the exterior walls, is obtained as follows:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

Columns.

For the columns 2 different types of harnesses are manufactured, a structural mesh harness and a union plates harness.

The structural mesh harness for the columns is obtained as follows:

-   1. Using a machine for the manufacture of meshes and wire-rod as raw     material, the electro welding of the structural mesh is carried out, -   2. The mesh is placed in a workstation to cut the leftovers, hollows     and overlaps in agreement with the specifications of the module, -   3. The assembly is inspected and it is sent the harness warehouse.

The union plates column harness (FIG. 41), is obtained as follows:

-   1. The cutting of the union plates and the rods for the anchorage of     the plates is carried out to the specified dimensions, -   2. The rods are bent using a universal bending machine, -   3. Finally the rods bent for anchorage are welded to the union     plates, and -   4. The assembly is inspected and it is sent to the harness     warehouse.

II. Manufacture of Modules.

The process of module manufacture consist of five working stations, called A, B, C, D and E, where specific operations are carried out; identified as sub-stages of the manufacture method being as follows (see FIGS. 3 and 4):

Station A.

-   Sub-stage 1. In Station A of the process, a mold of the interior     wall is submitted to a cleaning process, basic maintenance and     application of demoulding oil on the surfaces that have contact with     the concrete, and -   Sub-stage 2. The steal structural mesh and electrical harnessess are     assembled over the mold of the interior wall (FIG. 28 to 31).     Finally the union plates are installed on the flat roof (FIG. 39).     All this process is conducted according to the given specifications.

Station B.

-   Sub-stage 3. The platform and foundations mold are submitted to a     cleaning process, basic maintenance and application of demoulding     oil on the surfaces that have contact with the concrete, -   Sub-stage 4. A foundations mold is placed over the platform. This     metallic mold is formed by various sections depending on the size of     the foundations to be manufactured and in accordance with the given     specifications. -   Sub-stage 5. The beams of steal rod, which have been prefabricated     in the harness unit, are assembled over the metallic mold. Next, the     structural steal mesh harness, which has also been prefabricated in     the harness unit, is assembled (FIG. 35). This structural harness     has the corresponding electrical harness integrated. Finally the     plates and rods of union are installed into the walls. These     operations are conducted according to the manufacture     specifications. -   Sub-stage 6. In the concrete factory, the normal concrete is     prepared, preferentially the hydraulic concrete according to the     NMX-C155 norm and to the required design characteristics, which is     perfectly compatible with the cellular concrete. The concrete is     distributed in a hopper to the station in order to perform the     adding of the concrete over the foundations mold, -   Sub-stage 7. Once the adding has been completed (FIG. 6), the     vibration of the mixture is carried out to ensure the proper     consistency and distribution of the concrete. Subsequently a finish     and a superficial polish is given in accordance with the given     specifications, and -   Sub-stage 8. Once a finish has been given to the foundations, the     preliminary vapor curing is carried out under temperature, humidity     and time specifications to ensure the adequate setting of the     concrete.

Station C.

-   Sub-stage 9. At the end of the curing process, the platform is moved     to Station C, -   Sub-stage 10. The foundations is demoulded and the mold is returned     to Station B, -   Sub-stage 11. The interior wall mold (coming from Station A) is     placed over the foundations slab. This mold is metallic and it is     fabricated in one piece. Previously in Station A, the required     harnesses have been assembled over the interior wall mold, -   Sub-stage 12. The exterior wall mold is submitted to a cleaning     process, basic maintenance and application of demoulding oil on the     surfaces that have contact with the concrete, -   Sub-stage 13. The molding of the walls is completed using an     exterior wall mold that is closed over the interior wall mold (FIG.     10). This exterior wall mold is metallic and it is fabricated in two     pieces that are simultaneously slid with such a precision that     allows the hermetic closing of the mold walls. The dimensions of the     walls go in accordance with the given specifications, -   Sub-stage 14. In the concrete factory the cellular concrete is     prepared and it is distributed in a hopper to the station in order     to perform the adding of the concrete over the exterior walls mold, -   Sub-stage 15. When the adding has been completed, the surface is     leveled to ensure the specified slope for the walls, -   Sub-stage 16. The preliminary curing of the walls is carried out     under ambient temperature conditions. -   Sub-stage 17. After the concrete has settled for a determined time,     the demoulding of the interior wall is carried out and the mold is     returned to Station A. -   Sub-stage 18. The exterior wall mold is opened and it stays in     Station C waiting for the next molding and adding of walls cycle.

Station D.

-   Sub-stage 19. The platform is moved to Station D, -   Sub-stage 20. Once the walls have been demoulded, the final vapor     curing of the module is carried out under temperature, humidity and     time specifications.

Station E.

-   Sub-stage 21. The platform is moved to Station E. -   Sub-stage 22. Once the foundations-walls combination (FIG. 37) has     its nominal resistance, the process of module integration is carried     out, starting with the preparation of the surface and the placement     of the 2 columns over the foundations and resting on the walls. The     column-foundations-walls union is carried out through a welding     process of the union plates preciously placed on the foundations as     on the columns and exterior walls (FIGS. 39 and 41). -   Sub-stage 23. Next, the surface preparation and the assembly of the     flat roof are carried out. The flat roof-walls union is carried out     through a welding process of union plates previously placed on the     walls as on the flat roof, -   Sub-stage 24. The last phase of the module integration process is     carried out, which consists on the retouching, detailing and sealing     of the already integrated panel, -   Sub-stage 25. Once the module integration process has been carried     out, the platform is moved to the exterior of the factory, -   Sub-stage 26. The module over the platform is dried out at ambient     temperature for a determined time, -   Sub-stage 27. The module is removed from the platform and it is     transported to the module warehouse using a portico-type crane, -   Sub-stage 28. The platform is returned to Station B to start the     cycle again.

III. Manufacture of Flat Roofs and Panels.

Simultaneous to the fabrication of modules, the panel manufacture unit produces the flat roof and the columns for the integration of the module. The panel manufacture unit consists of the three workstations, identified as F, G and H, where specific operations are carried out, at the panel manufacture unit, identified as sub-stages of the manufacturing method, being defined as the interrelation of such stages as it is detailed as follows (see FIGS. 3 and 4):

Station F.

-   Sub-stage 29. The molds of the platform, the flat roof and the 2     columns are submitted to a process of basic maintenance and     application of demoulding oil on the surfaces that have contact with     the concrete, -   Sub-stage 30. The flat roof mold is placed over the platform. This     metallic mold is formed by various sections depending on the size of     the flat roof to be manufactured and in accordance with the given     specifications, -   Sub-stage 31. The polystyrene ‘bovedilla’ is placed over the     platform of the mold. The reinforcement armor and the structural     steal mesh harness, which has been prefabricated in the harness     unit, are placed over the ‘bovedilla’. This structural harness has     the corresponding electrical harness integrated. Finally, the union     plates are installed into the walls. -   Sub-stage 32. The 2 molds of the columns are placed over the     platform. The metallic mold of each column is formed by various     sections depending on the specifications given, -   Sub-stage 33. Later on, the steal structural mesh harness is     assembled, and the union plates are installed into the walls and the     foundations. -   Sub-stage 34. At the concrete factory, the normal concrete is     prepared, which is distributed in a hopper to the station in order     to perform the adding of the concrete over the molds of the flat     roof and the 2 columns, -   Sub-stage 35. Once the adding has been completed, the vibration of     the mixture is carried out to ensure the proper consistency and     distribution of the concrete. The leveling of the 2 columns is     carried out, and finally a finish is given to the flat roof, which     includes the configuration of the flat roof fence and the beam in     accordance with the given specifications, -   Sub-stage 36. Once the finish has been given to the flat roof and to     the 2 columns, the preliminary vapor curing is carried out under     temperature, humidity and time specifications to ensure the adequate     setting for the flat roof.

Station G

-   Sub-stage 37. At the end of the curing process, the platform is     moved to Station G, -   Sub-stage 38. After the setting of the concrete, the flat roof an     the columns are demoulded and the molds are returned to Station F, -   Sub-stage 39. Finally the curing of the concrete is carried out     under ambient temperature conditions.

Station H

-   Sub-stage 40. The platform is moved to Station H, -   Sub-stage 41. At Station H, the final vapor curing is carried out to     the flat roof as well as to the columns under temperature, humidity     and time specifications.     IV. Integration of the Columns into the Module.

This stage of the manufacture method consists of two sub-stages, carried out in a working station identified as I, which in detail are explained as follows (see FIGS. 3 and 4):

Station I.

-   Sub-stage 42. The platform is moved to Station I, -   Sub-stage 43. Using a crane system, the columns are transported to     Station E, where they are assembled into the module.

V. Assembly of the Flat Roof Over the Module Walls.

This stage also identified as the final stage or operational conclusion of the module manufacture method to build monolithic constructions, this stage is carried out as follows (see FIGS. 3 and 4):

-   Sub-stage 44. Using a crane system, the flat roof with the     integrated beam is transported to Station E where it is assembled     over the columns and module walls (FIGS. 40 and 42). Once the module     has been integrated, it is retouched and detailed.

VI. Transport and Storage of the Already Assembled Module for its Commercialization and Distribution (see FIGS. 3 and 4).

-   Sub-stage 45. Once the columns have been placed and the flat roof     has been integrated into the module, the platform is moved to the     exterior of the factory, -   Sub-stage 46. The platform is returned to Station F to reinitiate     the panel manufacture process.

The cellular concrete referred to in the different stages of this fabrication method, is a type of concrete with anhydrous calcium sulfate or anhydrite base and Portland cement, this cement does not present the undesirable effects associated to construction materials that use calcium sulfate, at the same time this cement develops high resistance to compression, conserving low volumetric weights that allow to use them as convenient cellular materials for the construction industry. Because of the high compression resistance that these type of cellular concretes develop, these can be used as light construction materials and at the same time constructive projects are provided with all the advantages that cellular materials can offer, because these also possess the common properties that characterize them.

However, for effects of the present invention any other cellular concrete can be used that provides high resistance to compression so that it can be used as structural material in the construction; it is preferable to use the improved cellular material compositions described by Prieto Gómez⁸, this materials develops high resistance to compression (≧110 Kg/cm²) and convenient volumetric weights (≧1200 Kg/m³), the cellular composition is basically a mixture of the following elements:

-   1. A cementation agent constituted by a mixture of     -   a) Portland cement or of clinker of Portland cement and     -   b) Anhydrous calcium sulphate, -   2. Silica sand, -   3. Polyester fiber, -   4. Foaming additive, and -   5. Water reducing agent.

The method of the present invention offers diverse advantages that are mainly reflected in the significant reduction of execution time to build diverse constructions, in the reduction of labor used and in the reduction of costs, during the construction as well as on the final building, without lowering the quality of buildings obtained, which comply with the quality and security standards established for themselves.

In addition, the method described here permits to obtain, at high volumes, modules for monolithic constructions that can be used afterwards for any type of construction, let it be for a complete building, an extension or used for remodeling. For example, if various working stations that form part of the present invention process are operated at the same time, a significant quantity of modules can be generated in sequence to supply the current demand for new houses. On the other hand, the production of modules at high volumes for construction allows that these can be offered to the construction industry at very competitive prices.

In this sense, the module fabrication process of the present inventions allows a production capacity of up to one module per hour, which under a working structure of 3 shifts permits to obtain up to 24 modules per day leaving the last stage of the manufacture. This taken to a continuous process of placement in the field allows putting 8 houses of 2 modules each per day.

Each of these houses requires around 1 week for the completion of connections and exterior details for it to be in possibilities of being inhabited; this depends on the speed of terrain preparation where the houses are going to be placed and on the speed of the constructor to finish the exterior details and all the connections of the building.

Because of the former, the process of the present invention allows to significantly reduce the fabrication time of any building in at least a 50% in comparison to the time invested in the traditional fabrication process to generate the same buildings. For example, if houses of two modules are generated with the invention process it is possible to obtain them in a 4 weeks average; whereas the generation of the same edifications with the traditional edification method results in an 8 weeks average.

As a way to illustrate the present invention, the following examples are presented, but these by no means limit the reach of the invention.

EXAMPLE 1 Obtaining of Construction for House from the Combination of 2 Modules of the Invention

Two modules of 3×5.5 mts were obtained according to the method of manufacture of modules described in the present application. In the unit of manufacture of harnesses (FIGS. 1 and 2), diverse structural, electrical, hydraulic, sanitary and of gas harnesses were obtained (FIG. 18), as well as to obtain the slab of corresponding foundation with the purpose of obtaining the 2 sub-modules that are observed in FIGS. 23 and 24. Submodule I is equipped with two interior panels assembled between in one of its ends to form a bathroom with access opening (FIG. 23), whereas sub-module II does not have interior panels (FIG. 24). Sub-module II counts on a left lateral wall equipped with an opening in arc form (FIG. 25), formed from the structural harness that is observed in FIG. 17; in the case of sub-module I, the left lateral wall was obtained from the structural harness shown in the FIG. 19, which has integrated an electrical harness that allows to provide electricity to the interior of sub-module I. The interior panels of sub-module I were assembled to the wall (FIG. 20) and to the foundation slab (FIG. 21) by means of weld of the located plates of union in the interior panels, walls and foundation slab. Integrated the interior panels, the roof slab previously obtained, it was integrated to the walls and it holds by means of union equipped with rods that are inserted in the roof slab and insured by mechanical means (FIG. 22). The assembled modules were finished by means of sealed of the cementitious material and later application of textured coverings. Later the obtained modules were placed in a vehicle equipped with platform and transported to the site of positioning by means of the use of a crane and resistant bands that were placed in the grooves located in the foundation and roof slabs of each one of the modules (FIG. 25). The obtained modules were assembled in the positioning site, previous made level preparation of the land, by means of the joint and subjection by weld of steel plates placed in the site of union of the modules, filling up the possible empty spaces between the modules with normal cement. The house obtained by means of the combination of these modules is shown in FIGS. 26 and 27. As it can be observed, the generated house is equipped with diverse delimited living spaces and the services necessary to living it.

EXAMPLE 2 Obtaining of Construction for Scholastic Classroom from the Combination of 2 Modules of the Invention

Two modules of 3×8 mts were obtained according to the method of manufacture of modules described in the present application. In the unit of manufacture of harnesses (FIGS. 3 and 4), diverse structural and electrical harnesses were obtained, as well as the columns and the corresponding foundation slab with the purpose of obtaining the 2 sub-modules that are observed in FIG. 36. Submodule I is equipped solely with windows, whereas sub-module II has windows and an access door to the interior.

The frontal wall of sub-module I was obtained from the structural harness shown in FIG. 29, whereas the frontal, lateral and posterior wall from submodule II they were obtained from the structural harnesses of FIGS. 28, 30 and 31. As it will be able to be observed, the structural harness of the lateral wall of sub-module II have an electrical harness that it allows to provide electricity to the interior of sub-module II.

The roof slab was obtained from the structural harness shown in FIG. 32 equipped with grooves for its transport, placing a beam of roof and plates of union to the walls of the sub-module (FIG. 33).

The foundation slab (FIGS. 34 and 35) was obtained from the structural harness shown in FIG. 35, equipped with cross-sectional beams (FIG. 36) and grooves for its transport.

Obtained the sub-module, the roof slab was assembled on the walls and held by means of union equipped with steel plates that were welded to each other (FIG. 39), whereas the roof beam was assembled on the columns of each module (FIG. 40) and assured by means of union equipped with rods (FIG. 41), allowing to good support and solidity of the structure of the module. A lateral view of the obtained sub-module I can be observed in FIG. 42.

The assembled modules were finished by means of sealed of the cementitious material and later application of textured coverings. Later the obtained modules were placed in a vehicle equipped with platform and transported to the site of positioning by means of the use of a crane and resistant bands that were placed in the grooves located in the foundation and roof slab of each one of the modules (FIG. 42). The obtained modules were assembled in the positioning site, previous made level preparation of the land, by means of the joint and subjection by weld of steel plates placed in the site of union of the modules, filling up the possible empty spaces between the modules with normal cement. The house obtained by means of the combination of these modules is in FIGS. 43 and 44. As it can be observed, the generated house is equipped with ample inner space and the electrical services necessary to use it.

EXAMPLE 3 Fire Proof Test of the Module Walls

One of the module walls described in example 1, as well as the walls manufactured with other construction materials were submitted to a fire proof test exposing the external faces of the walls to a source of heat during different time intervals according to norm NMX-C-307-1982. As it can be observed, the temperature of the external and internal walls was recorded and was graphed as a function of exposure time. As FIG. 45 shows, the side of all the walls exposed to the source of heat registered a temperature of in between 800 to 1,200° C., while the non-exposed side registered various temperatures depending on the type of the wall material (FIG. 46). In the case of the invention module wall (FIG. 46), the side not exposed to the fire registered the lowest temperature of all materials, reaching a maximum temperature of 60° C. with the highest exposure time. This contrasts with the temperature reached on the side of the wall exposed to the fire in the same time interval (close to 1,300° C.). In contrast with the behavior of the invention module walls, the walls elaborated with traditional construction materials, like concrete or block, reached temperatures above 100° C. on the side not exposed to the fire.

EXAMPLE 4 Thermal Test of Module Walls

The diverse wall materials tried out in the abovementioned example were submitted to a thermal test measuring the thermal conductivity K of each one of the materials (BTU in/ft² Fh). As FIG. 47 shows, the invention module wall (A series) turned out to be the most thermal of the materials by observing the lowest thermal conductivity value, while at the hydraulic concrete wall (E series) a complete different behavior was observed by registering the highest conductivity values. The rest of the materials registered significantly greater values than the observed for the walls of the invention module.

EXAMPLE 5 Obtainment of Diverse Edifications with the Invention Modules

Different sized modules were obtained according to the module manufacture method described in the present application. In accordance with the architectonic process of interest, the modules were placed and assembled at the construction residence site to grate varied edifications.

To create houses, individual modules measuring 3×7 m or 3×8 m equipped with interior panels, were used to create habitable spaces of 21 to 24 m² (see FIGS. 48 and 49), while diverse combinations of 2 modules of the same dimensions with interior panels (see FIGS. 27 and 50) were used to create habitable spaces of 33 to 36 m². In the same way two modules of different dimensions with interior panels were combined to create habitable spaces of 36 to 39 m² (FIGS. 51 and 52), while the diverse habitable spaces in between 49 a 57 m² (FIG. 53) were obtained combining 3 modules of different dimension with interior panels. As it can be observed the obtained houses include all services and are ready to be inhabited.

On the other hand 2 to 6 modules of 3×8 m were combined to create ample diverse habitable spaces for assorted uses. As it can be observed in FIGS. 54 to 58, the combination of these modules created edifications that can be uses as classrooms for schools, dinner school rooms, mass media halls, community centers, and school bathrooms. In some cases the modules have interior panels (see FIGS. 55, 57 and 58) that can be included into the module according to the corresponding architectonical project.

REFERENCES

-   1. Corredera Artacho Juan Antonio, et. al. 2005. Sistema de     construcción de edificios Pat PCT/ES2003/000431. -   2. Shen Grace, et. al. 2004. Convertible buildings and method of     production thereof. Pat PCT/GB2003/005482. -   3. Olesch, Grzergorz. 2005. A transportable modular building and     method of construction thereof. Pat PCT/PL2005/000015. -   4. De Quesada, Jorge. 2005. Pre-fabricated building modules and     method of installation. Pat US 2005/0108957. -   5. Vicino, Robert K. 1989. Method of holding monolithic building     structure. U.S. Pat. No. 4,799,982. -   6. Hopkins, George D. 1985. Apparatus for and method of     constructing, transporting and erecting a structure of two or more     stories comprised of a plurality of prefabricated core modules and     panelized room elements. U.S. Pat. No. 4,513,545. -   7. Coday, Jerry F. 1980. Precast concrete building module form. U.S.     Pat. No. 4,211,043. -   8. Prieto Gómez, Carolina, et. al. 2005. Composiciones mejoradas de     materiales celulares que contienen anhidrita y métodos para su     preparación. Pat MX PA/a/2005/001125. 

1. A monolithic structure of construction of the type that is integrated from a plurality of harnesses, foundation and roof, characterized because it comprise: a) walls (23) that conform a single piece to each other, b) a foundation slab (25), c) a roof slab (32), d) openings for doors (24) and windows (22), e) mechanical, electrical, hydraulic and sanitary elements, and elements of connection of gas, and f) elements of subjection and transport in the foundation and roof slabs (8, 27) that allow their transfer to the site of residence of the construction and which at the same time they allow the union and lateral joint of the monolithic structure of construction with another similar monolithic structure of construction, wherein the walls are united structurally to the foundation and roof slabs.
 2. The monolithic structure of claim 1, characterized because it is a monolithic module (13).
 3. The monolithic structure of claim 1, characterized because additionally it comprise a plurality of interior panels (21) from who can vary the dimensions, capacities and uses of the interiors of the monolithic structure.
 4. The monolithic structure of claim 1, characterized because it provides a heat insulation of the living zone of at least the double on magnitude that the provided by hydraulic cement.
 5. The monolithic structure of claim 1, characterized because the foundation slab (25) and roof slab (32) contains hydraulic concrete of high resistance, and the walls (23) contain cellular concrete.
 6. The monolithic structure of claim 5, characterized because the cellular concrete develops compressive strengths values of at least 110 Kg/cm² and volumetric weights of at least 1,200 Kg/m³.
 7. The monolithic structure of claim 1, characterized because it has a dimension of 4 to 7 mts wide by 3 to 4 mts in length.
 8. The monolithic structure of claim 1, characterized because additionally it comprise: a) columns (61) located in the ends of the wall (23) where the monolithic structure of construction with another similar monolithic structure of construction is united and assembled laterally, and b) a beam in the roof slab (66) located in the end of roof slab (32) where the monolithic structure of construction with another similar monolithic structure of construction is united and assembled laterally.
 9. The monolithic structure of claim 8, characterized because it has a dimension of 7 to 8 mts wide by 3 to 4 mts in length.
 10. A manufacture line method to obtain the monolithic structure of construction of claim 1 by means of a plurality of stations that comprise the stages of: a) manufacturing of harnesses, in this stage the different types of harnesses which are integrated into each one of the parts that form the monolithic structure are manufactured, in this stage the harnesses for the flat roof, interior panel, foundations and exterior walls are manufactured; b) manufacturing modules, where sub-stages along five working stations are carried out, called A, B, C, D and E; c) manufacturing interior panels and flat roof, simultaneous to the fabrication of modules, the panel manufacturing unit produce the interior panel and flat roof, wherein the panel manufacturing unit consists of three workstations, identified as F, G and H, and in where specific operations are carried out. d) Integrating of interior panels into the module, this stage of the manufacture method consists of two sub-stages only, carried out in the working station identified as I; e) assembly of the flat roof over the walls of the module, this stage is also identified as the final stage or the operational conclusion of the module manufacture method, and f) Transport and storage of the already assembled module for its commercialization and distribution.
 11. The method according to claim 10, characterized because in the stage of harness manufacture four types of harnesses are manufactured for the flat roof: a structural mesh harness, an electrical harness, a structural armor harness and a union plates harness.
 12. The method according to claim 10, characterized because in the stage of harness manufacture, several harnesses are manufactured for the interior panel: a structural mesh harness, an electrical harness and a union plates harness.
 13. The method according to claim 10, characterized because in the stage of harness manufacture, seven different types of harnesses are manufactured for the foundations: a structural inferior mesh harness, a structural superior mesh harness, an electrical harness, a structural bean harness, a sanitary harness, a union plates harness and a hydraulic harness.
 14. The method according to claim 10, characterized because in the stage of harness manufacture, several harnesses are manufactured for the exterior walls: a structural mesh harness, an electrical harness, a sanitary harness, a hydraulic harness, a gas harness, a union plates harness and a door harness.
 15. The method according to claim 10, characterized because in the stage of module manufacture, the following sub-stages are carried out in working station A: Sub-stage 1) a interior wall mold is submitted to a cleaning process, basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; and Sub-stage 2) the structural steal mesh harness, the electrical, sanitary, hydraulic and gas harness are assembled over the interior wall mold.
 16. The method according to claim 10, characterized as well because in working station A, the molds of windows, wall holes (vanos), doorframes and union plates to the interior panel and to the flat roof are placed over the mold of the interior wall.
 17. The method according to claim 10, characterized because in the stage of module manufacture in working station B, the following sub-stages are carried out: Sub-stage 3) the mold of the platform and the foundations are submitted to a cleaning process, basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; Sub-stage 4) The foundations mold is placed over the platform; Sub-stage 5) The beams of steal rod, which have been prefabricated in the harness unit, are assembled over the metallic mold; Sub-stage 6) At the concrete factory the normal concrete is prepared, which is distributed in a hopper to the station in order perform the adding of the concrete over the foundations mold. Sub-stage 7) Once the adding has been completed the vibration of the mixture is carried out to ensure the proper consistency and distribution of the concrete and subsequently a finish and a superficial polish is given in accordance with the given specifications; Sub-stage 8) Once the finish has been given to the foundations, the preliminary vapor curing is carried out under temperature, humidity and time specifications to ensure the adequate setting of the concrete.
 18. The method according to claim 17, characterized as well because in working station B, in between the sub-stages 5) and 6) the structural steal mesh harness that has also been prefabricated in the harness unit is assembled, this structural harness has the corresponding electrical harness integrated, next the hydraulic and sanitary harnesses are integrated into the structural harness, to finally install the plates and rods of union into the walls.
 19. The method according to claim 10, characterized because in the stage of module manufacture in working station C, the following sub-stages are carried out: Sub-stage 9) After the curing process, the platform is moved to station C; Sub-stage 10) the foundations is demoulded and the mold is returned to station B; Sub-stage 11) The interior wall mold (coming from station A) is placed over the foundations; Sub-stage 12) The exterior wall mold is submitted to a cleaning process, basic maintenance and application of desmoulding oil on the surfaces that have contact with the concrete; Sub-stage 13) The molding of the walls is completed using a exterior wall mold that is closed over the interior wall mold; Sub-stage 14) At the concrete factory the cellular concrete is prepared, which is distributed in a hopper to the station in order perform the adding of the concrete over the walls mold; Sub-stage 15) Once the adding has been completed the surface is leveled to ensure the specified slope for the walls; Sub-stage 16) The preliminary curing of the walls is carried out, staying there until the concrete has settled enough; Sub-stage 17) After the setting of the concrete for a determined time, the demoulding of the interior wall mold is carried out and the mold is returned to station A; and Sub-stage 18) The exterior wall mold is opened and it stays in station C waiting for the next molding and adding of walls cycle.
 20. The method according to claim 10, characterized because in the stage of module manufacture in working station D, the following sub-stages are carried out: Sub-stage 19) the platform is moved to station D; and Sub-stage 20) once the walls have been demoulded, the final vapor curing of the module is carried out under temperature, humidity and time specifications.
 21. The method according to claim 10, characterized because in the stage of module manufacture in working station E, the following sub-stages are carried out: Sub-stage 21) The platform is moved to station E; Sub-station 22) once the foundations-walls combination has its nominal resistance, the integration process of the module is carried out starting with the preparation of the surface and the assembly of the interior panel; Sub-stage 23) The preparation of the surface and the assembly of the flat roof is carried out; Sub-stage 24) The last stage of the module integration process is carried out, which consist on the retouching, detailing and sealing of the already integrated module; Sub-stage 25) Once the module integration process has been completed, the platform is moved to the exterior of the factory; Sub-stage 26) The module over the platform is dried out at ambient temperature for a determined time; Sub-stage 27) the module is moved away from the platform at it is transported to the module warehouse using a portico-type crane; Sub-stage 28) The platform is returned to station B to reinitiate the cycle.
 22. The method according to claim 21, characterized as well because in the stage of module manufacture in working station E, the interior panel-walls union is carried out through a welding process of the union plates previously placed on the foundations as on the exterior walls and the interior panel.
 23. The method according to claim 21, characterized as well because in the stage of module manufacture, in working station E, the flat roof-walls union is carried out through a welding process of the union plates previously placed on the walls as on the flat roof.
 24. The method according to claim 10, characterized because in stage of panel and flat roof manufacture, in working station F, the following sub-stages are carried out: Sub-stage 29) the mold of the platform and the flat roof are submitted to basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; Sub-stage 30) The flat roof mold is placed over the platform; Sub-stage 31) The polystyrene ‘bovedilla’ is placed over the platform of the mold; Sub-stage 32) At the concrete factory the normal concrete is prepared, which is distributed in a hopper to the station in order to perform the adding of the concrete over the flat roof mold; Sub-stage 33) When the adding has been completed, the vibration of the mixture is carried out to ensure the appropriate consistency and distribution of the concrete, subsequently a superficial finish is given, which includes the configuration of the flat roof fence in accordance with the given specifications; and Sub-stage 34) Once the finish has been given to the flat roof, a preliminary vapor curing is carried out under temperature, humidity and time specifications to ensure the required setting for the flat roof.
 25. The method according to claim 10, characterized because in stage of panel and flat roof manufacture, in working station G, the following sub-stages are carried out: Once the curing process is finished, the platform is moved to station G; Sub-stage 36) After the setting of the concrete, the flat roof is demoulded and the mold is returned to station F; Sub-stage 37) the platform and the interior panel mold are submitted to a cleaning process, basic maintenance and application of demoulding oil on the surfaces that have contact with the concrete; Sub-stage 38) The interior panel mold is placed over the platform; Sub-stage 39) The structural steal mesh harness that has been prefabricated in the harness unit is assembled; Sub-stage 40) At the concrete factory the cellular concrete is prepared, which is distributed in a hopper to the station in order to perform the adding of the concrete over the interior panel mold; Sub-stage 41) When the adding has been completed, a leveling to the surface and a superficial finish is given in accordance with the given specifications; Sub-stage 42) Once the finish has been given to the interior panel, the preliminary vapor curing is carried out under temperature, humidity and time specifications to ensure the appropriate setting of the concrete; and Sub-stage 43) After the setting of the concrete, the demoulding of the interior panel mold is carried out, the mold stays in station G waiting for the next molding and adding of the interior panel cycle.
 26. The method according to claim 10, characterized because in the stage of panel and flat roof manufacture, in working station H, the following sub-stages are carried out: Sub-stage 44) the platform is moved to station H; and Sub-stage 45) the final vapor curing of the flat roof as to the interior panel is carried out under temperature, humidity and time specifications.
 27. The method according to claim 10, characterized because in the stage of interior panel integration, in working station i, the following sub-stages are carried out: Sub-stage 46) The platform is moved to station I; and Sub-stage 47) using a crane system, the interior panel is transported to station E where the module is assembled.
 28. The method according to claim 10, characterized because in the stage of panel and flat roof assembly over the module walls, the following sub-stage is carried out: Sub-stage 48) using a crane system, the flat roof is transported to station E where it is assembled over the module walls, and once integrated into the module, it is retouched and detailed.
 29. The method according to claim 10, characterized because in the stage of transportation and storage of the already assembled module for its commercialization and distribution, the following Sub-stages are carried out: Sub-stage 49) once the flat roof and the interior panel have been integrated into the module, the platform is moved to the exterior of the factory; and Sub-stage 50) the platform is returned to station F to reinitiate the panel manufacture process. 